Hard tonneau cover

ABSTRACT

A hard tonneau cover having one or more sections is constructed of a framework of extruded rails with one or more section panels held by molded plastic trim strips installed on perimeter rails included in the framework. The cover is mounted above the cargo box of a pick-up truck by a plurality of striker-latch assemblies on one side of the cargo box, and hinge assemblies on the other side, each having components mounted to the cargo box side walls with universal clamp brackets. The panels are constructed of reinforced corrugated plastic which is covered by a color integrated film. A simplified connector plate is used to connect abutting ends of the rails in the fiamework. A peripheral seal extends down from the perimeter rails in which it is mounted to engage the top of the cargo box side walls and tailgate. Water drainage paths including drainage channels in the rails are provided to eliminate water from the panel surfaces.

CROSS REFERENCE TO RELATED APPLICATIONS

This invention claims the benefit of U.S. provisional Ser. No.60/455,999, filed Feb. 7, 2003.

BACKGROUND OF THE INVENTION

This invention concerns hard cover tonneaus for the cargo box of pick-uptrucks. In such tonneau covers, one or more panel sections are mountedon the side walls of the cargo box, and are hinged to allow raising ofone end or side of the cover sections which may also be disconnectedfrom the cargo box for removal. Such covers have typically beenspecifically been designed for a particular cargo bed configuration, andhave involved heavy panels of fiber glass reinforced molded resins.

Such hard covers are typically fit over plastic protection covers on thecargo box, and hinged to be raised for access to the cargo area, withgas struts used to support the weight of the opened cover.

The heavy weight of these tonneau covers has been an increasingdisadvantage as this reduces fuel economy and truck net payloadcapacity.

The proliferation of pick-up truck cargo box configurations has led toincreased costs due to the need for a greater number of custom designedcovers.

U.S. Pat. No. 6,082,806 suggests a construction using a tubular frameand thin panels fixed to the frame, allowing easy modification to fitvarious cargo bed sizes.

However, such an approach requires painting of the aluminum frame. Thecover panel affixed to the frame is subject to buckling due totemperature induced expansion and is difficult to replace if damaged.

It would be desirable to be able to match the quality of cover finish tovehicle finish, but this has heretofore not been possible due to thedifficulty in obtaining a distortion free cover surface acceptable tothe automobile manufacturers.

Another difficulty has to do with the service wear on the components andthe mating sheet metal surfaces due to the severe deflections of thecargo box during driving of the truck, particularly over rough roads andlong periods of time. Such wear occurs in the striker bars and hinges,and also where a cover seal scrubs against the cargo box painted sheetmetal.

Another problem is found in draining water from the cover to preventleakage into the cargo box. While attempts have been made to seal allthe joints, some seepage still occurs, and any bonding of a cover panelneeded to create a seal will create thermally induced distortions asmentioned above.

Installation and removal of the tonneau cover is often time consumingdue to the need to accurately align the cover with the cargo box and theneed for installing or removing numerous cover mounting components andfasteners.

It is the object of the present invention to provide a hard tonneaucover for a pick-up truck cargo box which is light weight and low incost to manufacture, but which has a high quality appearance compatiblewith the factory finish of the truck body.

It is another object of the present invention to provide a tonneau coverwhich can be readily sized and configured to be matched to a greatvariety of cargo box sizes and configurations, and having an easilyadjustable mounting system so that the cover may be readily installed inthe proper position on the cargo box.

It is a further object to provide a hard tonneau cover which canwithstand extended service in the field while maintaining properfunction of the components, and a good appearance while avoidingexcessive wear of the truck body finish.

Yet another object is to provide a hard tonneau cover which incorporatesa water drainage system which directs water off the cover to prevent anywater from penetrating into the cargo box, and which channels anyseepage along a path formed in the cover components away from the cargoarea.

SUMMARY OF THE INVENTION

The above recited objects and other objects which will become apparentupon a reading of the following specification and claims are achieved bya hard tonneau cover including a frame made up of a series of perimeterrails which can be cut to a selected size and assembled together into arectangular framework using corner pieces affixed to adjoining ends ofrails defining each corner. The perimeter rails are provided withinwardly protruding panel support ledges with an adjacent outer channel.

A rectangular panel sized to rest atop the support ledge of theperimeter rails is nonfixedly held on the framework with an edgeclearance space allowing for thermal expansion. The panel is preferablyconstructed from an “S-flute” corrugated plastic core having additionalstrengthening thin sheets of a suitable plastic or resin laminated ontoeach face. A covering color integrated plastic film providing a desiredcolor and finish is loose lay installed over the reinforced core toachieve an OEM compatible finish. Alternatively, the film can be bondedto the panel.

The perimeter rails are also each formed with one or more longitudinalouter slots which can slidably receive a one or two colored plastic trimstrips extending along and covering each rail so that the rails need notbe painted.

The trim strips each include an inwardly extending lip overlying theperimeter of the panel to nonfixedly secure the panel in position be andsealed against the panel. A skirt portion of a single trim strip or aseparate trim strip extends downwardly below the perimeter rail andoutside the cargo box engaging peripheral seal extending along thebottom of the perimeter rail so that a finished appearance is presented.

A matching molded plastic corner is attached to framework corner piecesat the outer corners of the rail framework, the corner overlapping thetrim strips at the corners and securing the trim strips in place.

The perimeter rails and corner pieces also are each formed with alongitudinal lower slot which receives a top bead on the elastomericperipheral seal which has a pair of spaced ribs engaging the cargo boxsurfaces to create a seal which is sufficiently compressible toaccommodate tilt-up of the tonneau cover, and which prevents entrance ofdirt. The ribs are maintained in contact with the cargo box surfaces toprevent scrubbing.

The panel supporting perimeter rail ledge has a downwardly facing teeslot underneath which receives bolt heads for mounting support bracketsfor hinges, latches, gas strut mounts, and connections to crossing railsand struts, anchor brackets, etc.

One or more crossing rails and struts extend between the perimeter railsat adjustably set positions by means of connector plates receiving boltsretained in perimeter rail tee slots and nuts, creating a sturdy butlight weight framework for supporting the panel. A central rail extendsin a lengthwise direction from a perimeter end rail to a crossing rail,and the crossing struts are mounted thereto and to an adjacent perimeterside rail.

Both the central and crossing rails may be of an extrusion of identicalcross section.

A series of universal clamp-on hinge latch fittings mount to the lip ofthe cargo box walls at any selected position, while mating strikers orhinges are attached by a cover bracket to the perimeter rails usingbolts on the ledge rail slots having head received. The same bracketsbolted to the perimeter are used to connect crossing slots in rails tothe perimeter rails by bolts held in slots in the crossing rails. Quickdisconnect hinge pins and strikers attach the cover to the cargo box bybeing mated to hinge brackets and latch assemblies on the cover.

The perimeter rails have water channels receiving water seepage passingthe trim strips overlying the panel perimeter and direct the same downto the corner pieces, which also receive water passing beneath thecorners, the water passing down a descending contour of the cornerpieces to drain out at a point past the peripheral seal.

The tonneau cover can be configured in various ways, such as with tworaisable cover sections, each section with separate rail frameworks. Inthis configuration, a fixed center section divides the cargo box intotwo areas, each occupied by front and rear cover sections. The rearcover section in this design may be hinged to the fixed center sectionby two hinge assemblies allowing the rear cover section to be raised up.

The forward panel section may be tilted up on one side by the clamp onhinge and latch brackets.

Gas struts are mounted to brackets secured to the cover section railsand a clamp on brackets on the cargo box to hold the cover in a raisedposition.

Trim strips are mated to slots in either side of the fixed centersection which overly the adjacent edges of the panel of the front andrear cover sections which also are each formed as transverse water draingutters which extend to end covers and a cup piece to drain waterpassing out from the channels past the perimeter of the cargo box seal.

The crossing rails are bowed to create a crowning of the cover to insurerapid draining of water from the cover.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a pictorial view of a hard tonneau cover using two openableand one fixed cover sections according to the invention shown installedon the cargo box of a pick-up truck depicted in phantom lines.

FIG. 2 is a pictorial view of the hard tonneau cover system shown inFIG. 1 with the rear cover section in a tilted up position.

FIG. 3 is a pictorial view of the hard tonneau cover system shown inFIGS. 1 and 2 with the front cover section shown tilted up from theright side.

FIG. 4 is a pictorial view of the hard tonneau cover with the rear coversection tilted up on hinges connected to a fixed.

FIG. 5 is a pictorial view of another embodiment of the hard tonneaucover according to the invention shown with a single openable coversection and a tool box mounted forwardly therefrom.

FIG. 6 is a pictorial view of a single cover section tonneau coveraccording to the invention.

FIG. 7 is a sectional view of a portion of a cover section of the hardtonneau cover according to the invention showing a striker installationon a universal mounting bracket and a mating latch mechanism mountedside thereof.

FIG. 8 is a sectional view of a rear portion of a raised cover sectionof the hard tonneau cover showing a hinge mounted on a universal clampon bracket, and a connection of a crossing rail to a perimeter rail by asupport connection bracket.

FIG. 9 is a sectional view of a rear portion of a cover section of thehard tonneau cover showing a striker on a universal mount disengagedwith a latch mechanism on a cover section.

FIG. 10 is a view of the middle of a cross section taken through a threesection hard tonneau cover according to the invention, with the rearcover section shown in phantom lines in a swung up position.

FIG. 11 is a plan view of a framework used in a three section hardtonneau cover according to the invention.

FIG. 12 is an exploded perspective fragmentary view of a connectionbetween two main support rails included in the framework shown in FIG.11.

FIG. 13 is an exploded perspective fragmentary view of a connectionbetween a strut rail and a central crossing rail included in theframework shown in FIG. 11.

FIG. 14 is an exploded pictorial view of a universal clamp on bracketand a striker assembly components mounted thereto.

FIG. 15 is an enlarged reverse exploded pictorial view of the strikerassembly components shown in FIG. 14.

FIG. 16 is a pictorial view of the striker assembly shown in FIGS. 14and 15.

FIG. 17 is a fragmentary exploded view of tonneau cover components atone corner.

FIG. 18 is a fragmentary exploded pictorial view of trim componentsincluded at the junction of the front, center, rear cover section of athree section tonneau cover according to the invention.

FIG. 19 is a fragmentary assembled view of portions of the componentsshown in FIG. 18 with a water drainage path indicated by a series ofarrows.

FIG. 20 is an enlarged fragmented cross sectional view through the hardtonneau cover combined with a tool box shown in FIG. 5.

FIG. 21 is a partially exploded pictorial view of one corner of atonneau cover according to the invention showing a water drainage pathby a series of arrows.

FIG. 22 is a fragmentary view of some of the hard tonneau covercomponents at the rear edge showing a water drainage path by a series ofarrows.

FIG. 23 is an enlarged sectional view of the full peripheral sealincluded in the hard tonneau cover according to the invention.

FIG. 24 is a pictorial view of the cargo box brackets used to mount thetonneau cover to the cargo box.

FIG. 25 is a plan view of the brackets and components shown in FIG. 24with a representation of the cargo box perimeter.

FIGS. 26A, 26B, 26C are side views of an angle piece part of a universalclamp on bracket with a hinge, striker, and gas strut anchor shownrespectively installed thereon.

FIG. 27 is an exploded sectional fragmentary view of a panelincorporated in the hard tonneau cover system according to theinvention.

FIG. 28 is an exploded pictorial view of components of one section of atonneau cover with a panel removed therefrom.

FIG. 29 is a pictorial view of the peripheral seal and auxiliary sealand components incorporated in the tonneau cover according to theinvention.

FIG. 30 is a plan view of a lock assembly used to operate the latchmechanism included in the hard tonneau cover according to the invention.

DETAILED DESCRIPTION

In the following detailed description, certain specific terminology willbe employed for the sake of clarity and a particular embodimentdescribed in accordance with the requirements of 35 USC 112, but it isto be understood that the same is not intended to be limiting and shouldnot be so construed inasmuch as the invention is capable of taking manyforms and variations within the scope of the appended claims.

Referring to drawing FIGS. 1-5, the present invention comprises a hardtonneau cover, in which a substantially rigid covering is provided forpick-up cargo box depicted in phantom lines.

The tonneau cover may be in multiple sections as for example, the threesection cover 10 shown in FIGS. 1 and 2, which includes the separatelyhinged rear cover section 12 and forward cover section 14. The rearcover section 12 is mounted on hinges (described below) at the rear sideof a fixed center section 16 lying between the two cover sections 12, 14so as to be able to be tilted up as seen in FIG. 2, with gas struts 20used to hold the rear cover section 12 in the up position shown.

The forward cover section 14 is mounted by hinge pin assemblies 22having hinge pins received in brackets mounted either side of the cargobox by a clamp on mount as will be described in detail hereinafter, soas to be readily installed in switchable positions to be able to betilted up on either the left or right side, as seen in FIGS. 3 or 4.

Latch-striker assemblies not shown in FIGS. 1-6 secure the cover sectionsides opposite the hinges, with the strikers also mounted to the cargobox using the universal mounting as is described in detail below. Asingle gas strut 20 is used to hold the forward cover section open.

FIG. 5 shows a larger single openable section cover 24, having a singlecover section 26 hinged to a fixed central section 28 along a forwardside. A tool box 30 is installed in the cargo box area forward of thefixed section 28.

FIG. 6 shows a cover 24A with a larger single openable section 26A and afixed section 28A.

Other cover arrangements are also possible such as a side hinged rearsection (not shown).

FIG. 7 shows some of the construction details of the tonneau cover 10.An extruded aluminum perimeter rail 32A, 32B is included in a forwardsection of a cover framework to be described which supports an overlyingstiff but resiliently bendable panel 34B without a fixed attachment toallow thermal expansion of the panel and to allow easy removal andreplacement.

The perimeter rails, including the side perimeter rails 32A, 32B of theforward cover section 12, are formed with various features allowinginterconnection with other framework members, a mounting of othercomponents, as well as a support for the panel 34B.

As seen in FIG. 11, two center crossing rails 94A, 94B and struts 136are used to increase the weight sustainable by the cover. Additionalcrossing rails and/or struts could be added to increase this capability.

All of the perimeter rails 32A, 32B, 96A, 96B, 190, 134 of the coverframework (FIG. 11) are preferably of an identical section.

The perimeter rail features include an inwardly extending ledge 36 (FIG.7) having an upper surface 38 on which an edge of the panel 34B rests,to be nonfixedly supported thereby. A tee slot 40 is formed underneaththe panel supporting surface 38 configured to slidably receive a makingfeature formed on support-connector piece 42.

The support-connector piece 42 can be located at any desired locationalong the slot 40 and secured thereat with bolts 44 and nuts 46.

The connector-support pieces 42 may serve several purposes, i.e., tomount an upper hinge component 45 on the cover, to connect cargo boxcrossing rails 94A, 94B, 98 and 112 to a perimeter rail 190, 32A, 32B,96A, 96B and 134 at the junction thereof, to mount latch assemblies andgas strut rod anchors to the framework. The connector-support pieces 42have an extension 43 which can be angled down when used to mount othercomponents to provide easier access to the fasteners.

In FIG. 8, a latching assembly 48 is mounted at the free end of asupport extension 43, operated by a cable 50 held on a bracket 52 alsoattached with bolts 54 and nuts 56.

The latching assembly 48 is engageable with a striker assembly 58mounted to the lip of a cargo box structure 60 by a clamp on universalmounting bracket 62 described below in further detail.

The perimeter rails such as side rails 32A, 32B shown in FIG. 8, alsoinclude a curved outer surface 64 formed with L-slots 66, 68 receivingmating features on a pair of interfit plastic trim strips 70, 72extending to overlie and cover the outer surface of the perimeter rails.The trim strips 70, 72 are preferably of molded plastic of a colormatching or compatible with the vehicle to eliminate any painting of theperimeter rails 32A, 32B. The trim strips 70, 72 could be made in onepiece, but making a separate upper strip 70 makes removal to release thepanel 34B easier and quicker.

The trim strip 70 includes a forward section 74 extending over the rearside of the panel 34A with a down turned lip frictionally engaging thesame.

The panel 34B is confined by the trim strips 70 but a clearance space atthe edges allows thermal expansion to preclude any resulting distortion,and also allows ready replacement of the panel 34B.

An overlay film 76 can be loose installed overlying the panel 34B andlikewise secured beneath the lip 72. The film 76 is constructed of acolor integrated plastic of a matching color or compatible with thevehicle finish to eliminate the need to paint any of the panels 34A, B,C. Suitable weather resistant plastics are available for thisapplication such as LEXAN™ and SLX™ by GE which can provide a class A,OEM compatible appearance in this installation.

Film 76 (typically 0.075-1.5 mm thick) can also be bonded to the panels34A, B, C.

Each of the lower trim strips 72 extends below the bottom edge of theperimeter rail on which it is installed to complete the covering of theperimeter rails.

The perimeter rail sections including rails 32A, 32B have a partiallycircular groove 78 into which is fit a top bead 80 of a hollow, readilycompressible elastomeric peripheral seal 82 partially concealed behindthe lower part of trim strip 72, seal 82 engaging the sheet metal of thetop of the cargo box wall, to exclude dirt and moisture. The seal 82 isdesigned to expand and twist as necessary to constantly maintain contactwith the cargo box surfaces as the truck body flexes in negotiating aroadway, which contact eliminates surface wear which would otherwiseoccur by rubbing of the seal 82 thereagainst.

The cover 10 is supported spaced above the side walls of the cargo box60 by the hinges, and strikers and latches, with the perimeter seal 82extending about the entire cargo box perimeter, sealing the interveningspace.

The seal 82 has hollow spaces 84 forming pleats creating the readycompressibility thereof as the associated section (12, 14) is tilted upabout a hinge, as seen in FIG. 7.

FIG. 8 shows a side hinged cover section, (here shown as forward coversection 14). A connector-support piece 42 secured to the perimeter rail32B is formed with a hinge pin receiving socket in which is inserted aquick release pin 88 which is received in a hinge clevis 89 formed on ahinge strap 90 attached to a second universal mounting bracket 62clamped to the lip of the cargo box 60, described in further detailbelow. The strap 90 attaching bolts are not shown in FIG. 8.

The connector-support piece 42 is here also used to connect theperimeter rail 32B to one end of the cross rail 112 forming one end ofthe forward cover section 14 by a series of four bolts 86 having theirheads received in downwardly facing tee slots in the crossing rail 112,similar to what is shown in FIG. 12 for crossing rails 98, 94. When usedfor this purpose, the connector-support piece extension 43 is angled tomatch the upward curving crossing rails 112.

FIG. 9 shows a released latch assembly 48 and striker 58 mounted to adownwardly angled extension plate 43 of a connector-support piece 42,with the cover section 14 shown in a partially raised position. Removalof the cover section 14 is also readily accomplished by also removingthe quick release hinge pins 88 on the other side wall, as will bedescribed.

FIG. 10 shows a lengthwise section through adjacent portions of theforward cover section 14 and the rear cover section 12, and the fixedcenter section 16.

The rear cover section 12 and forward cover section 14 are both spacedfrom the fixed center section 16, and trim-gutter pieces 92 areinstalled to bridge the gap therebetween.

The rear cover section 12 includes the center crossing rail 94A,preferably an aluminum extrusion, running lengthwise down the center ofthe framework 12A (FIG. 11) connected to a similarly shaped end crossingrail 98 by means of a bridge piece 100 connected by bolts 102 receivedin a tee slot 106 of the main support rail 94, and nuts 104.

As shown, the bridge piece 100 has a horizontally projecting tee headfeature 108 slid into a corresponding tee slot of the rail 98.

The front cover section 14 also includes a center crossing rail 94Bconnected to a similarly shaped perimeter rail 112 with a bridging piece114 joined in a similar manner as the rear cover section 12.

A trim strip 116 is mounted in a tee slot 110 extending along eachcrossing rail 98, 112.

Each trim strip 116 has an upper lip 118 which overlies an associatedpanel 34B or 34A to nonfixedly secure the same in position atop arespective rail 98, 112 (together with the outer perimeter trim strips70).

The fixed center cover section 16 similarly includes a crossing rail 120identical in configuration to rails 98 and 112 which is fixed to thecargo box side walls with a connector-mounting bracket (not shown) as isused to mount the striker and hinge components to the cargo box.

The gutter pieces 92 have an integral trim strip portion 122 capturing anarrow width panel 34C of the same construction as the panels 34A and B.

Water drainage holes 124 in each of the strips 116 and 122 allow waterto pass into gutters 92. A stiffer durometer plastic is used for thegutter portions than the strip portions 122.

A terminal edge 126 is urged into engagement with an understep of thetrim strips 116 just beyond the drain holes 124 to insure that anydraining water is captured.

The hinge straps 90 are pivoted to a bracket 128 secured to crossingrail 120 by bolts 130 having their heads captured in a tee slot in theunderside of the rail 120, with nuts 132 on the bolt ends protrudingthrough the bottom plate thereof.

The hinge straps 90 are secured at their opposite end by interfit teefeatures 133 and slots 135 in rail 98. Bolt and nut sets are used tolocate the straps 90 at any selected position along the rails 98, 120.

FIG. 11 shows the complete framework for a three section tonneau cover,providing support for the panels 34A, 34B, 34C, including frameworksections 12A, 14A and 16A.

Rear section framework 12A includes the pair of side perimeter rails96A, 96B, the forward end crossing rail 98 and the rear end perimeterrail 134 connected together at their meeting ends to form therectangular framework 12A.

The center crossing rail 94A extends lengthwise between the rear endperimeter rail 134 and the crossing rail 98, which is directly connectedat its ends to the midpoint of each of those rails.

The rear end of center crossing rail 94A is connected to the rear andperimeter rail 134 using a connector support piece 42 as describedabove.

A series of smaller width strut rails 136 are connected to the sideperimeter rails 96A, B to provide additional support for the panel 34A.The rear perimeter rail 134 is connected at its ends to a respectiverear end of a side perimeter rail 96A, B by a pair of connector pieces138. More crossing rails and struts could be added to increase theweight carrying capacity of the top.

FIG. 12 shows a connection between end crossing rails 112 and 98 to acentral crossing rail 94A, 94B by a connector plate 140, having a teefeature 142 slidably received in a side facing tee slot 144. The headsof a series of bolts 146 are slidably captured in parallel slots 148 ofrail 94A or B and attached to connector-plate 140 when nuts 150 areinstalled.

A pair of bolts 152 enter slot 154 of rail 98 and are secured with nuts.Thus, the rails 94A, 98 can be slidably positioned anywhere along theslots 154 but are securely fixed in any selected position. The rails94A, 98 can be trimmed to any size adapted to a particular truckconfiguration as well as being locatable anywhere along the length of aconnected rail to provide great adaptability to various truck bodies.

FIG. 13 shows the typical connection of strut rails 136 to centralcrossing rail 94A.

Small connector plates 158 each have a tee feature 160 slidably capturedin a side facing slot 162A or B on the rail 94.

Bolts 164 have their heads slidable in a slot 166 in the top of rails136 with nuts 168.

Bolt heads are also preinstalled in top slots 122 of the rail 94A andsecured with nuts to secure the rails 136 in any adjusted position.

These connections are typical of the rail connections in framework 12A,16A. Crossing rail 120 is connected to the truck cargo box structure bya hinge connection included in a connector support piece 42 at each endthereof. Corner connector pieces 138 (also shown in FIG. 16) havecontoured ends 180 fit beneath respective ends of rails 96B, 134 withbolt holes 182 aligned with holes 184 in the rails to allow installationof pairs of bolts 186 to secure the corner pieces 138.

Forward framework section 14A also includes connector plate pieces 138and a perimeter end rail 190 with strut rails 136. The lengthwisecrossing-rail 94B is connected at one end to the forward perimeter rail190 with a connector-support piece 42, and to crossing rail 112 with aconnection as shown in FIG. 12.

The members of framework sections 12A, 14A, 16A are covered by plastictrim including the trim strips 70, 72 described above, the trim strips70, 72 used on each of the perimeter rails 190, 134, 32A, 32B, 96B, 96B.

It is noted that each of the crossing rails 94A, 94B, 112, 120, 198 arepurposely bowed during the extrusion process to provide a crowning ofthe panels 34A, B, C towards the sides and the front and rear of thecover 10 in order to shed water. For this reason, the ledge surfaces 38of the support-connector pieces 42 may be tipped slightly upwardly to bealigned with the ends of the curved crossing rails.

The universal clamping bracket 62 is shown with a mounted strikerassembly 58 in FIGS. 7 and 14. A main clamping angle 193 has an upperleg 192 extending across the top of the cargo box side wall 60 and avertically descending lower leg 194 extending alongside the downturnedcargo box lip 61.

An inner clamping angle 196 is arranged on the inside of the cargo boxlip 61, with interposed cushioning members 198, 200 attached torespective clamping angles 190, 196.

Each clamping angle 193, 196 has a pair of slots 202, 204, aligned witheach other to allow insertion of a pair of bolts 206 to be secured withcage nuts 206. The slots 202 allow vertical adjustment of a hinge,striker or gas strut anchor as needed.

A series of three spacer strips 208 having holes 210 to receive thebolts 206. The mounting bracket 62 can thus be mounted vertically to awide variety of shapes of cargo box side walls 60.

A tee slot 212 is formed on the inside of the vertical portion of thevertical leg 194 of the clamping angle 193.

The heads of a pair of bolts 214 are received in the tee slot 212 andpass through slots in a striker bracket 216, secured with nuts 218.

A pair of ears 220 have aligned holes which receive a quick release pin232 secured with a colter clip 224.

A stainless steel sleeve is installed over the hardened steel pin 222and confined beneath guide washers 228 and a series of spacer washers230. Removing or switching sides of the spacer washers 230 allowsadjustment of the axial location of the gap between the guide washers228 to proper function with the latching assembly 48.

The stainless steel tube 226 rotates against the rotary latch pawls toreduce and even the wear thereon as the truck is driven, and resistscorrosion.

The universal clamping bracket 62 can also be used to connect a hingebracket 90 as shown in FIG. 7, allowing a fixed or hinged connection ofa perimeter rail 134, 96A, 96B, 32A, 32B or 190 with an end of acrossing rail 94A, 94B, 112, 98 or center rail 120 directly to the cargobox side wall 60 at any location along the rails or side wall to readilyadapt the tonneau cover to a wide variety of cargo box configurations.

In this case, the heads of a pair of bolts 222 (FIG. 26) are received ina slot 234 to pass through holes in the upper leg of the clamping angle193 and through a hinge mounting strap 236 secured with nuts 240mounting a removable hinge pin 88 between ears 238.

By providing a hinge connection on opposite sides of the center rail120, the hinge connection fixes the cover section 16 to the cargo box60.

FIGS. 24 and 25 show an example of the cargo box mounting systemcomponents for a three section system as shown in FIG. 1.

The forward cover section 14 is mounted to the cargo box 60 using anextended length main clamping angle 193A forming a combined universalclamping brackets 62 on each side which each mounts a striker assembly58 on one side and hinge brackets 90 on the other side of the cargo boxarea to receive the forward cover section 14.

Each extended length angle 193A extends further to allow mounting ofanother hinge bracket 90 on each side of the cargo box to mount thefixed center cover section 16.

This arrangement creates a secure connection of the entire tonneau coverto the cargo box 60 to create a stable support for all of the componentsof the cover 10.

A gas strut support 242 is provided by a separate clamping bracket 62 oneach side which is stabilized by an extension piece 240 secured to theextended bracket 193A.

A pair of striker assemblies 58 are mounted using mounting brackets 62at the rear of the cargo box area which is to receive the rear coversection 12.

FIG. 11 shows partial portions of a pair of gas struts 242 anchored atone end to a bracket 244 secured to strut rails 136.

A single gas strut 246 is connected at one end to a bracket 248installed on one side of the rail 112, the other end to a bracket 250mounted by bolts received in the inside facing tee slot of the extendedlength angle 143A.

A pair of lock assemblies 252 are mounted to a cover panel 34 and eachhave a pair of cables 50 leading to latch assemblies 48.

According to the tonneau cover of the present invention, the variousrails are covered with molded plastic trim including the strips 70, 72installed on all of the perimeter rails 32A, 32B, 96A, 96B, 190 and 134.

In addition, trim corners 254 which are fit between the ends of trimstrips 70, 22, secured with upwardly extending screws passing throughthe connector pieces 138 (FIG. 20). The corners 254 also prevent thetrim strips 70, 72 from shifting out of position. Removal of the cornersallows easy removal of strips 70 for replacement of the panels 34.

Water seepage which passes by the panel seals 74 is collected in achannel feature 256 in each of the perimeter rails 96A, 96B, 32A, 32Bwhich flows out over the corner pieces 138 and over the outer edge. Thisalso happens to water on the panels 34A, B, C seeping under the trimstrips. The drain path lies outboard of the peripheral seal 82 (FIG. 2)to insure that no water enters the cargo box 60.

FIGS. 18 and 19 show the trim components associated with the centersection 16 and the adjacent sides of cover sections 12, 14 on one sideof the cover, the opposite side having the same components.

A pair of end pieces 256 are each fit to one end of a perimeter rail96A, 32A (not shown in FIG. 18), overlapping the trim strips 70, 72, toone side and 116 at the top as well as the outside side wall of the trimgutter 92 aligned therewith.

A collector tray or cup 260 has two channel features which each slidablyreceive a respective gutter 92 so that draining water is guided to dripedges 26.

A cover 266 is fit atop the collector tray 260.

The perimeter skirt seal 82 (FIG. 29) extends around the perimeter,installed in the perimeter rails and corner pieces.

As shown in FIG. 29, in the region of the center section 16, short sealconnector sections 268 each are positioned at one end of the center rail120 by plugs 271 inserted in the seal hollows of the ends of theperipheral seal 82. Plugs 271 are compressed against the ends of theseal section 268 to accommodate movement of the sections 12, 14 whileinserting seal continuity when the sections 12, 14 are closed to finishthe complete coverage. A diverter strip 272 funnels water onto cup 260.

That is, the seal sections 268 bridge the gap between the ends of theperipheral seal 82 held in the perimeter rails.

FIG. 20 shows an installation with a tool box 274. In this case, thefixed center section 16 still has two gutters 92 attached, but therearmost gutter has a butt seal 276 clipped to the rear gutter wall tobear up against the side of the tool box 274 to create a water seal.

FIG. 23 show a preferred shape of the seal 82 in which a series ofsuccessively layered hollow accordion pleats 83A, B, C extend from amounting rib 85. These accommodate considerable compression and tiltingof the seal 82. The bottom of the pleat 83C has a pair of spaced apartribs 81 to engage and seal against surface 85. This shape minimizestrapping of dirt which can scratch the surface 85 if a seal scrubbedagainst the surface 85. Also, this seal shape accommodates side to sidemovement of the cover 10 without breaking contact with the surface,avoiding wear on the finish.

FIG. 27 shows the construction of a panel 34. The core 34-1 preferablycomprises a panel of corrugated plastic of the so called S-fluteconfiguration, which has improved stiffness in a direction transverse tothe lengthwise direction over a conventional parallel flute corrugatedplastic panel. This lightweight material, which has good resistance toimpacts, and also provides a greatly increased surface area for improvedbonding of the reinforcing layers when compared to honeycomb corespreviously used.

Such material is available under the trademark INTEPRO® from InteplastGroup, Ltd. Of Livingston, N.J.

Standard corrugated panels could also be used.

Additional layers 34-2A, 34-2B of a fiberglass material (FRP) islaminated to each face of the core 34-1.

These layers 34-2A, 34-2B could be smooth or texturized and coloredparticularly layer 34-2B.

An outer layer 34-3 of a color integrated film overlies the upperlaminated layer 34-2A. This film is of a type available in colorsmatching automotive paints and of a class “A” quality from GE Plasticsunder the mark LEXAN® or SLX™ in thicknesses of 0.075 mm to 1.5 mm. Aloose lay technique is preferred, in which the film 34-3 is trappedbeneath the trim strips but is otherwise not fastened to better presenta flat, class A appearance surface.

This also allows easy removal of the film for changing colors of forreplacement. Graphic imprints can also be easily incorporated on thefilm 34-3.

FIG. 28 illustrates the ease of changing an entire panel 34 or a colorfilm 34-3 by simply sliding out the upper trim strips 70 from theperimeter rails and removing corners 254.

One of the lock assemblies 276 is shown in FIG. 30, mounted to a panel34. Cables 50 are attached to a lock housing 278 by fittings 280 holdingthe outer cable casing. The actuation wires 290 extend to a respectiveend of a swivel bar 282 and are connected thereto.

A commercially available lock cylinder 284 is mounted within a can 286secured with a lock nut 280. Insertion of a key allows rotation of thebar 282 to pull wires 290 and release the connected latches 58.

This allows the associated cover section 12 or 14 to be swung up toobtain access to the cargo box 60.

A glow-in-the-dark plastic key 292 protrudes downwardly from the housing278 which connected to an extension rod 294 to allow a child to open thelatches 58 if he or she is trapped in the cargo box, providing a safetyfeature.

A weather cap 296 can be snap fit over the lock face as shown to preventwater from penetrating the lock and causing freezing, etc.

1. A hard tonneau cover for the cargo box of a pick-up truck comprising:a framework configured to be fit to said cargo box; a mounting systemattaching said framework to said cargo box; at least one lightweight,stiff but reseliently bendable panel overlying an opening in saidframework to cover the same; said panel having a perimeter extendingover a series of perimeter rails included in said framework defining atleast in part said opening; a series of trim strips attached to andoverlying said perimeter rails, said trim strips each having a portionextending over said perimeter of said panel to retain the same on saidframework perimeter rails, said framework and said trim strips confiningsaid panel in position over said opening in said frameworks.
 2. Theassembly according to claim 1 wherein said perimeter rails comprisealuminum extrusions.
 3. The assembly according to claim 1 wherein eachof said perimeter rails includes a slot mating with a lengthwise featureon an associated respective one of said trim strips.
 4. The assemblyaccording to claim 1 wherein said perimeter rails are each formed with aledge surface on which an associated panel edge rests with an endwiseclearance freely allowing thermal expansion of said panel.
 5. Theassembly according to claim 4 wherein said trim strips press against anupper surface of said perimeter edge one or more panels to retain thesame in position against said perimeter rail surfaces.
 6. The assemblyaccording to claim 1 wherein said one or more panels are comprised ofcorrugated plastic having additional strengthening layers bonded to eachopposite face.
 7. The assembly according to claim 6 wherein a colorintegrated film is disposed over an outer exposed side of said panel. 8.The assembly according to claim 7 wherein said film layer loosely liesatop said exposed side of said panel.
 9. The assembly according to claim1 wherein said mounting system includes a plurality of hinge andstriker-latch assemblies each including components thereof mounted tosaid cargo box by a bracket clamped to a side wall lip of said cargo boxand also including mating components mounted to said cover framework.10. The assembly according to claim 9 wherein said framework issupported spaced above said cargo box walls and holds a peripheral sealextending down from said framework perimeter rails engaged with a topsurface of said cargo box walls.
 11. The assembly according to claim 10wherein said peripheral seal is shaped with a vertical series of hollowpleats providing easy compressibility.
 12. The assembly according toclaim 11 wherein a bottom end of said peripheral seal is formed withspaced apart contact surfaces to minimize trapping of dirt.
 13. Theassembly according to claim 10 wherein a bottom slot is formed alongsaid perimeter rails and said seal includes an enlarged upper end slidinto said slot to be retained therein.
 14. The assembly according toclaim 1 wherein said framework includes at least one crossing railattached at either end to a respective perimeter rail.
 15. The assemblyaccording to claim 14 wherein said perimeter rails includes one or moretee slots, and wherein crossing rail also includes one or more teeslots, and connection pieces interconnect said crossing rail to saidperimeter rails utilizing components received in a tee slot of saidcrossing and perimeter rails.
 16. The assembly according to claim 15wherein said connection hardware includes a connector plate having a teefeature receive in a tee slot of one of said perimeter or crossing railand bolts having heads captured in a tee slot of another of saidcrossing or perimeter rail.
 17. The assembly according to claim 16further including strut rails extending from a crossing rail to aperimeter rail and connected at either end thereto.
 18. The assemblyaccording to claim 10 wherein said perimeter rails are each formed withlengthwise drainage channels receiving water on said one or more panelsleaking past said trim strips, said channels leading to a corner of saidframework, a corner piece connecting each adjacent end of two meetingperimeter rails, said corner piece receiving water from said channelsand directing water out beyond said peripheral seal.
 19. The assemblyaccording to claim 1 wherein each perimeter rail includes a ledgesurface on which a panel perimeter rests and further including an outersurface downwardly curved, said trim strips conforming to said outercurved rail surface.
 20. The assembly according to claim 19 wherein saidperimeter rails outer surface has one or more lengthwise slots thereinreceiving a protruding lengthwise extending portion of a trim strip tobe mounted thereto.
 21. The assembly according to claim 20 wherein twooverlapped trim strips extend along each perimeter rail, each slidablyreceived in a respective groove in an associated perimeter rail.
 22. Theassembly according to claim 1 wherein said cover includes a plurality ofseparate sections including a rear section and a center section, saidrear section hinged to said center section, said center section fixed tosaid cargo box by said mounting system.
 23. The assembly according toclaim 22 wherein said framework includes a rear framework sectioncomprised of a rear perimeter rail extending over a rear tailgate ofsaid cargo box and two side perimeter rails each connected at one end toa respective end of said rear perimeter rail, each side perimeter railextending partially along opposite side walls of said cargo box, and acrossing rail connected at opposite ends to an end of each sideperimeter rail opposite said end connected to said rear perimeter end toform a rectangular framework section, a rear section panel overlyingsaid rear framework section.
 24. The assembly according to claim 23wherein said center section comprises a center crossing rail fixed ateither end to said cargo box by a pair of clamping brackets each endclamped to a respective side wall of said cargo box, and a center paneloverlying said center crossing rail.
 25. The assembly according to claim24 wherein said crossing rail of said rear framework section comprisesan extruded shape formed with a series of lengthwise slots and mountinga pair of hinge components by elements received in one or more of saidslots.
 26. The assembly according to claim 22 further including aforward section including a forward framework section comprised of aforward perimeter rail overlying a forward wall of said cargo box and apair of side perimeter rails overlying a portion of said cargo box sidewalls each connected at one end to a respective end of said forwardperimeter rail, and a rear crossing rail connected at opposite ends toan end of a respective side perimeter rail opposite an end connected tosaid forward perimeter rail, and a forward section panel mounted oversaid forward section framework.
 27. The assembly according to claim 26wherein said forward section is supported above said cargo box by a pairof latch-striker assemblies on one side thereof and a pair of hinges onthe other side thereof, included in said mounting system.
 28. Theassembly according to claim 26 wherein said rear and forward sectionsspaced from said center section and a gutter trim piece interposedtherebetween each extending to each cargo box side wall to carry waterover said cargo box side walls.
 29. The assembly according to claim 9wherein each of said striker latch assemblies includes a strikercomponent including a bracket clamped to a cargo box side wall, a pinheld in spaced bracket ears, and a tube revolvable on said pin.
 30. Theassembly according to claim 29 wherein said pin is a quick removal pinable to be readily removed from said bracket.
 31. The assembly accordingto claim 29 further including a pair of guide washers on said pin andtube and a series of spacer washers on each end of said pin and tubelocating said guide washers axially thereon.
 32. The assembly accordingto claim 9 wherein said mounting system brackets comprises an outerangle piece having a horizontal leg overlying the top of said cargo boxside wall and a vertical leg extending outside an inner lip of saidcargo box side wall, and an inner angle piece secured thereto with ahorizontal leg extending beneath said cargo box side wall top and avertical leg extending inside of said cargo side wall inner lip, saidvertical legs drawn together by threaded fasteners to be clamped to saidlip.
 33. The assembly according to claim 32 further including a seriesof spacers interposed between said vertical legs of said inner and outerangle pieces.